Acidic zirconia sol and production method of the same

ABSTRACT

There is provided an acidic zirconia sol having compatibility of particle properties and binding properties, and a production method of the same. The acidic zirconia sol includes zirconia particles (a) having a particle diameter ranging from 20 to 300 nm in a content of 90 to 50% by mass, based on the mass of all zirconia particles, and zirconia particles (b) having a particle diameter of less than 20 nm in a content of 10 to 50% by mass, based on the mass of all zirconia particles.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a divisional application of U.S. PatentApplication No. 11/918,134, now U.S. Pat. No. 7,691,910, filed Feb. 8,2008, which in turn is a U.S. national stage application ofPCT/JP2006/307660, filed Apr. 11, 2006. Each of the prior applicationsis incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present invention relates to an acidic and stable zirconia sol and aproduction method of the same.

BACKGROUND ART

Conventional methods for obtaining a zirconia sol include: a method forheat-hydrolyzing a zirconium salt aqueous solution, a method for addinghydrogen peroxide to a zirconium salt aqueous solution and heating theresultant solution, and a method for heating zirconium hydroxide in abasic region.

There is disclosed a method for hydrolyzing a reaction product betweenzirconium ammonium carbonate and a chelating agent (for example,oxyphenols, amino alcohols, oxyacids, polycarboxylic acids,oxyaldehydes, amino acids, and 62-diketones) (see, Patent Document 1).

There is disclosed a production method of a basic zirconia solincluding: maintaining an aqueous suspension containing zirconiumhydroxide in a heated state at 80° C. or more until the crystallinity ofproduced zirconia becomes 80% or more to obtain an aqueous suspensioncontaining crystallized zirconia; and adding to the obtained aqueoussuspension, a basic compound containing nitrogen (primary amine,secondary amine, or quaternary ammonium hydroxide), a hydroxide of analkali metal or alkaline earth metal (see, Patent Document 2).

There is disclosed a production method of a zirconia sol including:causing a precipitate by adding a base to a zirconium salt aqueoussolution; adding thereto, a hydroxide of an alkaline earth metal or anaqueous solution thereof to obtain a suspension; and heat-aging theobtained suspension at a temperature of 90 to 200° C. (see, PatentDocument 3).

There is disclosed a production method of a zirconia sol including:heating a zirconium salt aqueous solution having a molar ratio ofanion/metal of 0.5/1 to 4/1 to 120 to 300° C. and cooling the heatedsolution to room temperature; and adjusting the pH value of the solutionto 2 to 6 (see, Patent Document 4).

There is disclosed a production method of a zirconia sol including:adding hydrogen peroxide to a zirconium salt aqueous solution having aconcentration of 0.05 to 2.0 mol/L in an amount which is about half theamount of zirconium in the aqueous solution or more in the molar ratio;heating the resultant solution to 80 to 300° C.; and adding to thesolution further a base, such as ammonia, or treating the solution withan ion-exchange resin or the like (see, Patent Document 5).

There is disclosed a production method of zirconia-based fine particlesincluding: heating to 80 to 250° C. and hydrolyzing a zirconium saltaqueous solution to form crystalline zirconia fine particles; separatingby precipitation method a part of the thus-formed crystalline zirconiafine particles having a secondary aggregated particle diameter ofapproximately 1000 Å or more on average from another part of thethus-formed crystalline zirconia fine particles to produce a zirconiasol; and subjecting the produced zirconia sol individually or incombination with another metal compound to a thermal treatment at atemperature of 1000° C. or less (see, Patent Document 6).

-   Patent Document 1: Japanese Patent Application Publication No.    JP-A-3-174325-   Patent Document 2: Japanese Patent Application Publication No.    JP-A-64-083519-   Patent Document 3: Japanese Patent Application Publication No.    JP-A-60-176920-   Patent Document 4: U.S. Pat. No. 2,984,628 Specifications-   Patent Document 5: Japanese Patent Application Publication No.    JP-A-58-079818-   Patent Document 6: Japanese Patent Application Publication No.    JP-A-58-217430

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

Although various production methods of zirconia sol are developed, manyof them are production methods in which a zirconium salt is hydrolyzedin an acidic region and heated. In such production methods, a reactionsystem becomes unstable depending on formed fine particles and is likelyto cause a gelation.

Further, by a method in which a zirconium salt is hydrolyzed in analkali region using ammonium carbonate or an alkali hydroxide, althoughparticles are formed, a large amount of sediment is deposited with timeand the reaction system becomes slurry, so that a completely stable solcannot be obtained.

It is an object of the present invention to provide an acidic zirconiasol having compatibility of particle properties and binding properties;and a production method of the same by subjecting a liquid medium towhich a zirconium salt is added to a hydrothermal treatment, using as araw material, a zirconia sol, preferably an alkaline zirconia sol.

Means for Solving the Problems

According to a first aspect of the present invention, an acidic zirconiasol contains zirconia particles having a particle diameter of less than20 nm in a content of 10 to 50% by mass, based on the mass of allzirconia particles.

According to a second aspect, a production method of the acidic zirconiasol of the first aspect includes: a first process in which an alkalinezirconia sol (A) and a zirconium salt (B) are mixed in a mass ratio(Bs/As) ranging from 0.2 to 5.0 of a mass of a solid content (Bs) whichis converted into an amount of ZrO₂ in the zirconium salt (B) to a massof a solid content (As) which is converted into an amount of ZrO₂ in thealkaline zirconia sol (A); and a second process in which the resultantmixture is reacted at 80 to 250° C. to produce an acidic zirconia sol.

According to a third aspect, in the production method of the secondaspect, as the zirconium salt (B) in the first process, a zirconium saltaqueous solution or a pH-adjusted zirconium salt aqueous solution isused.

According to a fourth aspect, in the production method of the secondaspect, as the zirconium salt (B) in the first process, an aqueoussolution of zirconium oxychloride, zirconium oxynitrate, zirconiumoxysulfate, zirconium oxyacetate, or a mixture thereof is used.

According to a fifth aspect, in the production method of the secondaspect, as the zirconium salt (B) in the first process, an aqueoussolution containing a zirconium ammonium carbonate aqueous solution andan acid is used, or after a zirconium ammonium carbonate aqueoussolution has been used, the resultant mixture to which an acid is addedis used.

According to a sixth aspect, in the production method of the secondaspect, as the zirconium salt (B) in the first process, an aqueoussolution obtained by adding an alkali to an oxyzirconium salt aqueoussolution is used.

According to a seventh aspect, in the production method of the secondaspect, as the zirconium salt (B) in the first process, an aqueoussolution obtained by anion-exchanging an oxyzirconium salt aqueoussolution is used.

According to an eighth aspect, in the production method of the secondaspect, as the zirconium salt (B) in the first process, an aqueoussolution obtained by adding zirconium hydroxide or zirconiumoxycarbonate to an oxyzirconium salt aqueous solution is used.

According to a ninth aspect, in the production method of any one of thesecond to eighth aspects, the alkaline zirconia sol (A) used in thefirst process has a pH value of 8 to 12.

According to a tenth aspect, in the production method of any one of thesecond to eighth aspects, the mixing in the first process is performedby a method of adding the alkaline zirconia sol (A) into an aqueoussolution of the zirconium salt (B).

According to an eleventh aspect, in the production method of the ninthaspect, the mixing in the first process is performed by a method ofadding the alkaline zirconia sol (A) into an aqueous solution of thezirconium salt (B).

According to a twelfth aspect, in the production method of any one ofthe second to eighth aspects and the eleventh aspect, the acidiczirconia sol obtained in the second process has a pH value of 0.1 to5.0.

According to a thirteenth aspect, in the production method of the ninthaspect, the acidic zirconia sol obtained in the second process has a pHvalue of 0.1 to 5.0.

According to a fourteenth aspect, in the production method of the tenthaspect, the acidic zirconia sol obtained in the second process has a pHvalue of 0.1 to 5.0.

According to a fifteenth aspect, the production method of any one of thesecond to eighth aspects, the eleventh, thirteenth, and fourteenthaspects, further includes a third process in which desalting andconcentration of a solution of the acidic zirconia sol obtained in thesecond process is performed.

According to a sixteenth aspect, the production method of the ninthaspect, further includes a third process in which desalting andconcentration of a solution of the acidic zirconia sol obtained in thesecond process is performed.

According to a seventeenth aspect, the production method of the tenthaspect, further includes a third process in which desalting andconcentration of a solution of the acidic zirconia sol obtained in thesecond process is performed.

According to an eighteenth aspect, the production method of the twelfthaspect, further includes a third process in which desalting andconcentration of a solution of the acidic zirconia sol obtained in thesecond process is performed.

Effects of the Invention

The present invention is an acidic zirconia sol obtained by a method inwhich an alkaline zirconia sol and a zirconium salt are mixed and aliquid medium of the resultant mixture is subjected to a hydrothermaltreatment.

The acidic zirconia sol is obtained by a production method including: afirst process in which an alkaline zirconia sol (A) and a zirconium salt(B) are mixed in a mass ratio (Bs/As) ranging from 0.2 to 5.0 of a massof a solid content (Bs) which is converted into an amount of ZrO₂ in thezirconium salt (B) to a mass of a solid content (As) which is convertedinto an amount of ZrO₂ in the alkaline zirconia sol (A); and a secondprocess in which the obtained mixture is reacted at 80 to 250° C. toproduce an acidic zirconia sol, and contains zirconia particles having aparticle diameter of less than 20 nm in a content of 10 to 50% by mass,based on the mass of all zirconia particles. That is, the acidiczirconia sol contains zirconia particles (b) having a particle diameterof less than 20 nm in a content of 10 to 50% by mass, based on the massof all zirconia particles and the residue (90 to 50% by mass) iszirconia particles (a) having a particle diameter ranging from 20 to 300nm.

The alkaline zirconia sol (A) used in the first process as a rawmaterial is converted into zirconia particles (a) having a particlediameter ranging from 20 to 300 nm in the acidic zirconia sol. A part ofthe zirconium salt (B) is converted into zirconia particles (b) having aparticle diameter of less than 20 nm in the acidic zirconia sol and theresidue thereof is coated on the periphery of the particles of thealkaline zirconia sol (A) as a raw material and converted into zirconiaparticles (a). Accordingly, the obtained acidic zirconia sol containszirconia particles (b) having a particle diameter of less than 20 nm ina content of 10 to 50% by mass, based on the mass of all zirconiaparticles and the residue (90 to 50% by mass) is zirconia particles (a)having a particle diameter ranging from 20 to 300 nm.

The acidic zirconia sol has particle properties and bonding propertiesand in a cured form of the acidic zirconia sol, large particles andsmall particles are packed densely, so that the adhesion thereof with anadherend is high and the surface hardness thereof is also high.

As described above, the acidic zirconia sol according to the presentinvention has such a property that the particle diameter distributionthereof is wide and stable, so that the acidic zirconia sol of thepresent invention can be applied in many applications, such as a binderfor molding processing of various refractories, a binder for variouscatalysts, an impregnation treatment, a paint for coating, as well asmolding processing of an inorganic fiber such as a ceramic fiber,shaping of a mold for a precision casting, a surface treatment of afiber and a fuel cell.

BEST MODES FOR CARRYING OUT THE INVENTION

The present invention is an acidic zirconia sol containing zirconiaparticles having a particle diameter of less than 20 nm in a content of10 to 50% by mass, based on the mass of all zirconia particles.

The production method of the acid zirconia sol according to the presentinvention includes: a first process in which an alkaline zirconia sol(A) and a zirconium salt (B) are mixed in a mass ratio (Bs/As) of a massof a solid content (Bs) which is converted into an amount of ZrO₂ in thezirconium salt (B) to a mass of a solid content (As) which is convertedinto an amount of ZrO₂ in the alkaline zirconia sol (A) of 0.2 to 5.0;and a second process in which the obtained mixture is reacted at 80 to250° C. to produce an acidic zirconia sol.

In the first process, it is preferred that an alkaline zirconia sol (A)and a zirconium salt (B) are mixed in a mass ratio (Bs/As) of a mass ofa solid content (Bs) which is converted into an amount of ZrO₂ in thezirconium salt (B) to a mass of a solid content (As) which is convertedinto an amount of ZrO₂ in the alkaline zirconia sol (A) of 0.2 to 5.0,preferably 0.5 to 3.0, more preferably 0.5 to 2.5.

By setting the value of Bs/As within a range of 0.5 to 3.0, morepreferably 0.5 to 2.5, an acidic zirconia sol having more improved shelfstability can be obtained.

As the alkaline zirconia sol (A) used as a raw material of the presentinvention, an alkaline zirconia sol having a pH value of preferably 8 to12 can be used. As the alkaline zirconia sol, a known zirconia sol canbe used, however, the following alkaline zirconia sols can be preferablyused.

The alkaline zirconia sol (A) as a raw material can be obtained by forexample a method including: a process in which a zirconium salt isheated at 60 to 110° C. in an aqueous medium containing a carbonate saltof quaternary ammonium, and a process in which the resultant liquidmedium is subjected to a hydrothermal treatment at 110 to 250° C.

Examples of the carbonate salt of quaternary ammonium includes (NR₄)₂CO₃and NR₄HCO₃ and these compounds can be used individually or incombination thereof. Examples of the quaternary ammonium ion in thecarbonate salt of quaternary ammonium include those having an (1 to 18C) hydrocarbon group and examples of the (1 to 18 C) hydrocarbon groupinclude a saturated or unsaturated chain hydrocarbon group and analicyclic or aromatic cyclic hydrocarbon group. Examples of thesaturated or unsaturated chain hydrocarbon group include a methyl group,an ethyl group, a propyl group, an isopropyl group, an octyl group, adecyl group, an octadecyl group, an ethynyl group and a propenyl group.Examples of the cyclic hydrocarbon group include a phenyl group, a tolylgroup, a styryl group, a benzyl group, a naphtyl group, and an anthrylgroup. Among them, the quaternary ammonium ion has preferably an (1 to 4C) hydrocarbon group, such as a methyl group, an ethyl group, a propylgroup, and an isopropyl group and tetramethyl ammonium hydrogencarbonate composed of four methyl groups is preferred.

When as the above carbonate salt, a carbonate salt containing anotherammonium ion than a quaternary ammonium ion is used, also a stablezirconia sol (A) cannot be obtained. For example, when a tertiaryammonium ion such as (CH₃)₃HN, a secondary ammonium ion such as(CH₃)₂H₂N, a primary ammonium ion such as (CH₃)H₃N and an ammonium ionwhich becomes NH₄ are used, a satisfactorily stable zirconia sol (A)cannot be obtained.

In the production of the alkaline zirconia sol (A) as a raw material, acarbonate salt of a quaternary ammonium ion is commercially available inthe form of an aqueous solution having a content of 30 to 60% by massthereof. Particularly, an aqueous solution having a content of acarbonate salt of quaternary ammonium of 44.5% by mass which isconverted into a content of quaternary ammonium hydroxide are easilycommercially available. The concentration of a carbonate salt ofquaternary ammonium is obtained by a method of measuring in aconcentration converted into a concentration of quaternary ammoniumhydroxide.

Examples of the zirconium salt used for the production of the alkalinezirconia sol (A) as a raw material include an oxyzirconium salt, such aszirconium oxychloride, and zirconium oxycarbonate. Particularly,zirconium oxycarbonate is preferred.

A carbonate salt of quaternary ammonium is added to an aqueous medium toproduce an alkaline aqueous medium. At this time, when instead of acarbonate salt of quaternary ammonium, quaternary ammonium hydroxide isused, a satisfactorily stable zirconia sol cannot be obtained, but beobtained in a slurry in which two phases are separated. Further, forproducing an alkali aqueous medium, when another alkali source, such assodium hydroxide is used, also a stable hydrolyzed product of zirconiumsalt cannot be obtained, but only an unstable one is obtained and whensuch an unstable hydrolyzed product is subjected to a hydrothermaltreatment, also a stable zirconia sol (A) cannot be obtained. However,it is possible to use another alkali source in combination with acarbonate salt of quaternary ammonium, such as water-soluble inorganicsalts (for example, sodium hydroxide, potassium hydroxide, lithiumhydroxide, and ammonia), amines (for example, n-propyl amine,monoethanol amine, and triethanol amine), water-soluble organic bases(for example, monomethyltriethyl ammonium hydroxide, and tetramethylammonium hydroxide), and other carbonate salts than a carbonate salt ofquaternary ammonium (for example, ammonium carbonate). When an alkalinesubstance is used in combination with a carbonate salt of quaternaryammonium, a mass ratio between a carbonate salt of quaternary ammoniumand another alkaline substance is preferably (a carbonate salt ofquaternary ammonium):(another alkaline substance)=1:0.01 to 1.

The process (i) for producing the alkaline zirconia sol (A) as a rawmaterial is a process in which in an aqueous medium containing acarbonate salt of quaternary ammonium, a zirconium salt is heated at 60to 110° C.

An aqueous medium used for the process (i) for producing the alkalinezirconia sol (A) as a raw material, has a pH value of 9 to 12 and acarbonate salt of quaternary ammonium in the aqueous medium has acontent of 10 to 35% by mass. The zirconium salt in the aqueous mediumhas a content as ZrO₂ of 5 to 20% by mass. When a heating temperature inthe process (i) is 60° C. or less, a satisfactory hydrolysis is notprogressed and even when the obtained hydrolyzed product is subjected toa hydrothermal treatment, a stable zirconia sol (A) cannot be obtained.On the other hand, when the process (i) is performed at 110° C. or more,there is no aging time of the hydrolysis, which means that the reactionis transferred directly to a hydrothermal treatment and which is notpreferred. The process (i) is performed for usually 1 to 20 hours.

The process (ii) for producing the alkaline zirconia sol (A) as a rawmaterial is a process in which after the process (i), a hydrothermaltreatment is performed at 110 to 250° C. When performed at 110° C. orless, the hydrothermal treatment becomes unsatisfactory and whenperformed at 250° C. or more, a large-scaled apparatus becomes required.The hydrothermal treatment is performed using an autoclave apparatus.The process (ii) is performed usually for 1 to 20 hours. Through thehydrothermal treatment, a hydrolyzed product of a zirconium salt isconverted into zirconia particles. The zirconia particles obtainedthrough the process (ii) have a size ranging from 20 to 300 nm asobserved by a transmission electron microscope.

A liquid through the process (ii) is an alkali having a pH value of 8 to12 and can be satisfactorily used as a zirconia sol (A) as it is.However, by performing a process (iii) in which the liquid through theprocess (ii) is washed with pure water using an ultrafiltrationapparatus as an additional process, unnecessary salts can be removed, sothat a high-purity alkaline zirconia sol (A) can be obtained.

An alkaline zirconia sol (A) through the process (iii) has physicalproperty values, such as a pH value of 8 to 12, a specific surface areaof 50 m²/g to 300 m²/g, a concentration of 30 to 60% by mass, anelectric conductivity of 2000 to 10000 μS/cm and a viscosity of 1 to 30mPa·s. Further, the particle diameter distribution thereof is in therange of 20 to 300 nm.

The alkaline zirconia sol (A) can stably exist under a condition of 50°C. for one month or more.

The alkaline zirconia sol (A) as a raw material through the process(iii) may contain, if desired an additive, such as water-solubleinorganic salts (for example, sodium hydroxide, potassium hydroxide,lithium hydroxide, and ammonia), amines (for example, n-propyl amine,monoethanol amine, and triethanol amine) and water-soluble organic bases(for example, monomethyltriethyl ammonium hydroxide, and tetramethylammonium hydroxide).

The alkaline zirconia sol (A) having a pH value ranging from 8 to 12 anda concentration ranging from 1 to 20% by mass can be used in the firstprocess of the present invention.

In the first process for the production of the zirconia sol of thepresent invention, the zirconium salt (B) is used as a zirconium saltaqueous solution or a pH-adjusted zirconium salt aqueous solution.

In the first process, in a case (B-1) where the zirconium salt (B) isused as an aqueous solution of zirconium oxychloride, zirconiumoxynitrate, zirconium oxysulfate, zirconium oxyacetate or a mixturethereof in mixing with the alkaline zirconia sol (A), an acidic aqueoussolution of an oxyzirconium salt, such as zirconium oxychloride(ZrOCl₂), zirconium oxynitrate (ZrO(NO₃)₂), zirconium oxysulfate(ZrOSO₄), and zirconium oxyacetate (ZrO(CH₃COO)₂) is used. In the case(B-1), an oxyzirconium salt aqueous solution having a pH value of 0.1 to3.0 and a concentration of 1 to 20% by mass is used.

In the first process, in a case (B-2), the zirconium salt (B) is used asan aqueous solution containing a zirconium ammonium carbonate aqueoussolution and an acid in the mixing with the alkaline zirconia sol (A),or the zirconium salt (B) is used as a zirconium ammonium carbonateaqueous solution in the mixing with the alkaline zirconia sol (A) and anacid is added to the resultant mixture. In the case (B-2), there are twocases, such as a case where the zirconium salt (B) is used as an acidicaqueous solution of an oxyzirconium salt obtained by adding an acid tozirconium ammonium carbonate ((NH₄)₂ZrO(CO₃)₂)) in the mixing with thealkaline zirconia sol (A), and a case where the zirconium salt (B) isused as zirconium ammonium carbonate ((NH₄)₂ZrO(CO₃)₂)) in the mixingwith the alkaline zirconia sol (A) and to the resultant mixture, an acidis added. Examples of the acid used here include inorganic acids, suchas hydrochloric acid, nitric acid, and sulfuric acid and organic acids,such as formic acid, and acetic acid. Particularly, inorganic acids,such as hydrochloric acid, nitric acid, and sulfuric acid are preferred.In the case (B-2), a zirconium ammonium carbonate aqueous solutionhaving a concentration of 1 to 15% by mass is used. An acidic aqueoussolution obtained by adding an acid to zirconium ammonium carbonate hasa pH value of 0.1 to 4.0. Further, in the case where zirconium ammoniumcarbonate ((NH₄)₂ZrO(CO₃)₂)) is used in the mixing with the alkalinezirconia sol (A) and to the resultant mixture, an acid is added, theaddition of an acid is performed until the pH value of the mixture fallswithin a pH range of 0.1 to 4.0.

In the first process, in a case (B-3) where the zirconium salt (B) isused as an aqueous solution obtained by adding an alkali to anoxyzirconium salt aqueous solution in the mixing with the alkalinezirconia sol (A), an acidic oxyzirconium salt aqueous solution obtainedby adding an alkaline component to an oxyzirconium salt aqueous solutionis used. An oxyzirconium salt used here can be one compound or acombination of two or more compounds which is (or are) selected fromthose described in the case (B-1). Further, examples of the alkalinecomponent include water-soluble inorganic salts such as sodiumhydroxide, potassium hydroxide, lithium hydroxide, and ammonia,carbonates such as sodium carbonate and potassium carbonate, andwater-soluble organic bases such as monomethyltriethyl ammoniumhydroxide, and tetramethyl ammonium hydroxide. In the case (B-3), thesolution having a pH value of 0.1 to 4.0 and a concentration of 1 to 15%by mass is used.

In the first process, in a case (B-4) where the zirconium salt (B) isused as an aqueous solution obtained by anion-exchanging an oxyzirconiumsalt aqueous solution in the mixing with the alkaline zirconia sol (A),an acidic colloidal solution of extremely fine zirconium oxide having aparticle diameter of less than 20 nm which is obtained byanion-exchanging an oxyzirconium salt aqueous solution is used. Anoxyzirconium salt used here can be one compound or a combination of twoor more compounds which is (or are) selected from those described in thecase (B-1). Further, the anion-exchange can be performed by contactingthe solution with an anion-exchanging resin. For example, theanion-exchange is performed by a method of passing the oxyzirconium saltaqueous solution through a column packed with a hydroxyl group typeanion-exchanging resin. In the case (B-4), the extremely fine colloidalsolution has a pH value of 0.1 to 4.0 and a concentration of 1 to 20% bymass.

In the first process, in a case (B-5) where the zirconium salt (B) isused as an aqueous solution obtained by adding zirconium hydroxide orzirconium oxycarbonate in the mixing with the alkaline zirconia sol (A),an acidic aqueous solution obtained by adding zirconium hydroxide(ZrO(OH)₂) or zirconium oxycarbonate (ZrOCO₃) to the oxyzirconium saltaqueous solution described in (B-1) is used. In the case (B-5), theaqueous solution has a pH value of 0.1 to 4.0 and a concentration of 1to 20% by mass.

In a method of mixing the alkaline zirconia sol (A) and the zirconiumsalt (B), as the use of the zirconium salt (B), either one methodselected from the group of (B-1) to (B-5) or a combination of aplurality of methods selected from the group (B-1) to (B-5), can beused.

Among the above-mentioned methods using the zirconium salt (B), themethod (B-2) in which an aqueous solution of the zirconium salt (B) usedin mixing with the alkaline zirconia sol (A) is rendered acidic byadding nitric or hydrochloric acid to basic zirconium ammonium carbonate((NH₄)₂ZrO(CO₃)₂) is used. Also, a method in which an alkali such asammonia is added to the zirconium salt (B), a method in which a solutionis treated with an ion-exchanging resin or a method in which zirconiumhydroxide or zirconium oxycarbonate is added ((B-3) to (B-5)) is used.By subjecting the zirconium salt (B) to these treatments ((B-2) to(B-5)), the balance between oxyzirconium ions and acid ions in thezirconium salt (B) is changed and the hydrolysis reaction isaccelerated. Further, in the case where an alkali such as ammonia isadded to the zirconium salt (B) or in the case where a solution istreated with an ion-exchanging resin, with respect to the zirconium saltobtained by these treatments, it is necessary that the oxyzirconium ionremains to have a positive charge, so that it is desired that a treatedsolution has a pH value of 5 or less, preferably 4 or less, morepreferably 3 or less. In a case where zirconium hydroxide or zirconiumoxycarbonate is added to the zirconium salt (B), it is preferred thatthe mass ratio (Bs/Bs′) of a mass of a solid content (Bs) which isconverted into an amount of ZrO₂ in the zirconium salt (B) to a mass ofa solid content (Bs′) which is converted into an amount of ZrO₂ inzirconium hydroxide or zirconium oxycarbonate is 1.0 to 10.0, preferably2.0 to 10.0. Further, when a solution obtained by adding zirconiumhydroxide or zirconium oxycarbonate to the zirconium salt (B) is heated,the hydrolysis reaction is further accelerated, which is more preferred.

A method in which the zirconium salt (B) is mixed with the alkalinezirconia sol (A) in the state of an aqueous solution is preferred. Anaqueous solution of the zirconium salt (B) having a concentration of 1to 20% by mass is preferably used.

In the first process of the present invention, the alkaline zirconia sol(A) and the zirconium salt (B) are mixed in a mass ratio (Bs/As) of amass of a solid content (Bs) which is converted into an amount of ZrO₂in the zirconium salt (B) to a mass of a solid content (As) which isconverted into an amount of ZrO₂ in the alkaline zirconia sol (A) of 0.2to 5.0.

The mixing of the alkaline zirconia sol (A) and an aqueous solution ofthe zirconium salt (B) is performed by adding the alkaline zirconia sol(A) to an aqueous solution of the zirconium salt (B).

When the mass ratio Bs/As is less than 0.2, the amount of the alkalinezirconia sol (A) becomes too large and it is feared that the productioncost becomes high. On the other hand, when the mass ratio Bs/As is morethan 5.0, the content of particles (b) having a particle diameter ofless than 20 nm becomes large, so that the stability of the sol islowered.

In the second process of the present invention, the mixture obtained inthe first process is reacted at 80 to 250° C. When the reaction isperformed at less than 80° C., it does not become a satisfactoryhydrothermal treatment. On the other hand, when the reaction isperformed at more than 250° C., a large-scaled reaction apparatusbecomes required. The hydrothermal treatment is performed using anautoclave apparatus. The second process is performed for usually 1 to 20hours. Through the second process, the acidic zirconia sol of thepresent invention is obtained.

The acidic zirconia sol obtained through the second process has a pHvalue of 0.1 to 5.0, preferably 0.1 to 2.0.

Although zirconia particles of the alkaline zirconia sol (A) grow alittle in an acidic zirconia sol formed through the second process, theyare zirconia particles (a) having a particle diameter substantiallywithin the range of 20 to 300 nm. With respect to the zirconium salt(B), a part thereof is converted into zirconia particles (b) having aparticle diameter in the range of less than 20 nm in an acidic zirconiasol formed through the second process and another part thereof is coatedon particles of the alkaline zirconia sol (A) as a raw material to beconverted into zirconia particles (a). The particle diameter can beconfirmed using a transmission electron microscope. The ratio betweenthe zirconia particles (a) and the zirconia particles (b) can bedetermined by a method including: treating a formed acidic zirconia solusing a centrifugal separator so that the resultant supernatant liquidcontains the zirconia particles (b); and measuring the solid content inthe supernatant liquid. The quantity of zirconia particles (a) can bedetermined by measuring the solid content in the resultantprecipitation.

A part of the zirconia particles (b) in the acidic zirconia sol iszirconia particles having a small particle diameter which can beconfirmed using an electron microscope and another part thereof whichcannot be confirmed using an electron microscope is extremely finecolloids of zirconium oxide.

The acidic zirconia sol obtained by a production method of the presentinvention contains the zirconia particles (b) having a particle diameterof less than 20 nm in a content of 10 to 50% by mass, based on the massof all zirconia particles and the residue (90 to 50% by mass) is thezirconia particles (a) having a particle diameter ranging from 20 to 300nm.

The zirconia particles (b) having a diameter of less than 20 nmcontained in a liquid consist of zirconia particles having a smallparticle diameter and extremely fine colloids of zirconium oxide whichare difficult to be distinguished by an electron microscope. However,even when it is a substance difficult to be distinguished by an electronmicroscope, by evaporating to dryness a liquid in which the substance iscontained, the substance can be confirmed to be zirconium oxide by aX-ray diffraction, so that the substance contained in the acidiczirconia sol which is difficult to be distinguished by an electronmicroscope, is considered to be extremely fine colloids of zirconiumoxide.

A zirconia sol containing the zirconia particles (a) having a particlediameter ranging from 20 to 300 nm can individually stably exist.However, a zirconia sol containing the zirconia particles (b) having aparticle diameter of less than 20 nm or extremely fine colloids ofzirconium oxide are difficult to exist individually stably and in aproduction process thereof, a gelation is likely to be caused.Accordingly, by a method of only mixing a zirconia sol containing thezirconia particles (a) having a particle diameter ranging from 20 to 300nm, a zirconia sol containing the zirconia particles (b) having aparticle diameter of less than 20 nm and extremely fine colloids ofzirconium oxide, the acidic zirconia sol according to the presentinvention cannot be obtained.

In the alkaline zirconia sol (A) used in the present invention, thesurface of the zirconia particles is charged negatively in an alkaliregion. On the other hand, in the zirconium salt (B), such as zirconiumoxynitrate, an oxyzirconium ion ZrO²⁺ is charged positively. Forexample, in the first process for mixing the alkaline zirconia sol (A)and the zirconium oxynitrate (B), by adding the alkaline zirconia sol(A) into an aqueous solution of the zirconium oxynitrate (B),oxyzirconium ions ZrO²⁺ of the zirconium oxynitrate (B) are adsorbed onthe surface of zirconia particles of the alkaline zirconia sol (A), andin the second process, by subjecting the resultant mixture to ahydrothermal treatment, fine zirconia particles are formed on thesurface of the zirconia particles derived from the alkaline zirconia sol(A). A part of these fine zirconia particles is chemically bonded withthe zirconia particles derived from the alkaline zirconia sol (A) duringthe hydrothermal reaction, and by the amount of the fine particlescoated on the zirconia particles derived from the alkaline zirconia sol(A), the zirconia particles derived from the alkaline zirconia sol (A)grow as the particles. Another part of the fine zirconia particlesbecomes apart from the zirconia particles derived from the alkalinezirconia sol (A), and exists individually in the liquid or are bonded toeach other by the hydrothermal reaction to grow as the particles.

However, when an aqueous solution of the zirconium oxynitrate (B) isadded to the alkaline zirconia sol (A) in the first process, since theaqueous solution of the zirconium oxynitrate (B) is an acidic solution,pH of the alkaline zirconia sol (A) is lowered, so that depending on thecase, the alkaline zirconia sol (A) becomes acidic and the negativecharge on the surface of the zirconia particles are lowered. Dependingon the case, the surface of the zirconia particles becomes chargedpositively and consequently, the ability of the particle surface toadsorb the oxyzirconium ions ZrO²⁺ derived from the zirconium salt (B)is lowered, so that on the surface of the zirconia particles, theoxyzirconium ions ZrO²⁺ are unlikely to be converted into fine zirconiaparticles. Rather, the oxyzirconium ions ZrO²⁺ are not fixed to thezirconia particles and float freely in the liquid. The floatingoxyzirconium ions are hydrolyzed during the hydrothermal reaction, sothat fine zirconia particles and extremely fine colloids are likely tobe gelated each other.

However, so long as the problem of such a gelation can be overcome, evenby a method of adding an aqueous solution of the zirconium salt (B) tothe alkaline zirconia sol (A), the present invention can be performed.That is, for suppressing such a gelation, by a method in which under acondition of stirring with a high revolution number using an impellerhaving a shearing force, such as a disper, an aqueous solution of, forexample the zirconium oxynitrate (B) is added to the alkaline zirconiasol (A), an acidic zirconia sol can be produced. By adding the zirconiumsalt (B) under such a condition, the oxyzirconium ions ZrO²⁺ are likelyto be adsorbed uniformly on the surface of the zirconia particles, sothat fine zirconia particles and extremely fine colloids are unlikely tobe gelated each other.

According to the present invention, the obtained acidic zirconia sol hasa wider particle diameter distribution than that of the alkalinezirconia sol used as a raw material, and is an acidic zirconia sol inwhich large particle zirconia, small particle zirconia and zirconiaextremely fine colloids are mixed present. While an acidic zirconia solconsisting of only small particle zirconia and zirconia extremely finecolloids has low stability, the acidic zirconia sol according to thepresent invention containing large particle zirconia, and small particlezirconia and zirconia extremely fine colloids which have been formed inthe presence of the large particle zirconia has high stability.

By heat-hydrolyzing the zirconium salt (B) in the presence of thealkaline zirconia sol (A) as a raw material, the acidic zirconia sol ofthe present invention containing the large zirconia particles (a) andthe small zirconia particles (b) containing zirconium oxide extremelyfine colloids can be obtained.

Even when the second process of the present invention is performedwithout using the alkaline zirconia sol (A) as a raw material and withusing only an aqueous solution of the zirconium salt (B), the eventualproduct is only a gel-shaped substance and a stable zirconia sol cannotbe produced.

In the present invention, after the second process, the third processfor the desalting and the concentration can be performed. As thedesalting, there can be mentioned a method using an ultrafiltrationmembrane and by this method, while washing with water, the acidiczirconia sol can be concentrated to a concentration of 10 to 40% bymass.

The obtained acidic zirconia sol is a zirconia sol having a pH value of0.1 to 5.0, preferably 1.5 to 4.5.

The pH value of the acidic zirconia sol can be both lowered by adding anacidic substance, such as hydrochloric acid, nitric acid, and aceticacid as a pH adjuster and elevated by adding an alkaline substance, suchas sodium hydroxide, ammonia, and quaternary ammonium to convert theacidic zirconia sol to an alkaline zirconia sol.

EXAMPLES Measuring Method of Content of Zirconia Particles HavingDiameter Range of Less than 20 nm in Acidic Zirconia Sol

By diluting the acidic zirconia sol with pure water, 30 g of a dilutedliquid having a content as ZrO₂ of 0.5% by mass was prepared. Twoaliquots of 15 g of the diluted liquid were weighed and taken into anindividual predetermined vessel.

The vessel containing the diluted liquid was subjected to a centrifugalseparator (trade name: SRX-201; manufactured by Tomy Seiko Co., Ltd.) tosubject the diluted liquid to a centrifugal separation at 20000 rpm forone hour. After the centrifugal separation treatment, the sample in thevessel was separated into two parts, such as a part of a substantiallycolorless and transparent supernatant and a part of precipitations withwhite color. The part of a supernatant was observed using a transmissionelectron microscope, there were observed only zirconia particles havinga diameter of less than 20 nm and no zirconia particle having a diameterof 20 nm or more was observed. Thereafter, all amount of the supernatantwere recovered and the mass of the recovered liquid was measured. Allamount of the recovered liquid were transferred into a porcelaincrucible and, water was evaporated at 100° C. from the liquid.Thereafter, the crucible was baked for 30 minutes in an electric oven of800° C., and after cooled, the mass of the residue in the crucible wasweighed. All of zirconia particles having a particle diameter of lessthan 20 nm were defined to be present in the supernatant and from thefollowing equation, the content of zirconia particles having a particlediameter range of less than 20 nm was calculated.Content of zirconia particles having a particle diameter range of lessthan 20 nm (%)=[(Residue of supernatant after calcination)/(Solidcontent converted into ZrO₂ in the diluted liquid charged into thevessel)]×100

Example 1

Into a 3 L glass-made vessel, 342.9 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1976.8 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 80.3 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of10:4, and a pH value of 0.9 (first process). The mixture was transferredinto a glass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours(second process). The substance obtained after the reaction had no geland was completely converted into a sol. The substance had a content of5% by mass as ZrO₂ and a pH value of 0.7. Next, the sol was washed usingan ultrafiltration apparatus while adding pure water gradually to thesol and was concentrated to thereby obtain an acidic zirconia sol havinga content of 20.3% by mass as ZrO₂. The obtained sol had a pH value of3.5, a B type viscosity of 982 mPa·s (measured with No. 3 rotor at after60 sec), a content of NO₃ of 3.5% by mass, a particle diameter of 3 to300 nm as measured by a transmission electron microscope, a particlediameter of 108 nm as measured by a dynamic light scattering method, anda content of zirconia particles having a particle diameter range of lessthan 20 nm in all zirconia particles of 46%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was90.4%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

Example 2

Into a 3 L glass-made vessel, 342.9 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1976.8 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 80.3 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of10:4, and a pH value of 0.9 (first process). The mixture was transferredinto a glass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours(second process). The substance obtained after the reaction had no geland was completely converted into a sol. The substance had a content of5% by mass as ZrO₂ and a pH value of 0.7. Next, the sol was washed usingan ultrafiltration apparatus while adding pure water gradually to thesol and was concentrated to thereby obtain an acidic zirconia sol havinga content of 23.2% by mass as ZrO₂. The obtained sol had a pH value of2.3, a B type viscosity of 18.6 mPa·s (measured with No. 1 rotor atafter 60 sec), a content of NO₃ of 4.3% by mass, a particle diameter of3 to 300 nm as measured by a transmission electron microscope, aparticle diameter of 85 nm as measured by a dynamic light scatteringmethod, a content of zirconia particles having a particle diameter rangeof less than 20 nm in all zirconia particles of 47%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was96.0%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

Example 3

Into a 3 L glass-made vessel, 240.0 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 2019.5 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 140.5 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of10:10, and a pH value of 1.2 (first process). The mixture wastransferred into a glass-lining coated autoclave and was subjected to ahydrothermal synthesis reaction while stirring the mixture at 140° C.for 3 hours (second process). The substance obtained after the reactionhad no gel and was completely converted into a sol. The substance had acontent of 5% by mass as ZrO₂ and a pH value of 1.0. Next, the sol waswashed using an ultrafiltration apparatus while adding pure watergradually to the sol and was concentrated to thereby obtain an acidiczirconia sol having a content of 25.6% by mass as ZrO₂. The obtained solhad a pH value of 3.3, a B type viscosity of 13.0 mPa·s (measured withNo. 1 rotor at after 60 sec), a content of NO₃ of 3.3% by mass, aparticle diameter of 3 to 300 nm as measured by a transmission electronmicroscope, a particle diameter of 86 nm as measured by a dynamic lightscattering method, a content of zirconia particles having a particlediameter range of less than 20 nm in all zirconia particles of 31%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was97.3%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

The sol was preserved at room temperature for 3 months and at this time,the sol had a B type viscosity of 34.8 mPa·s (measured with No. 1 rotorat after 60 sec).

Example 4

Into a 3 L glass-made vessel, 400.0 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1953.2 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 46.8 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of10:2, and a pH value of 1.0 (first process). The mixture was transferredinto a glass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours(second process). The substance obtained after the reaction had no geland was completely converted into a sol. The substance had a content of5% by mass as ZrO₂ and a pH value of 0.7. Next, the sol was washed usingan ultrafiltration apparatus while adding pure water gradually to thesol and was concentrated to thereby obtain an acidic zirconia sol havinga content of 17.3% by mass as ZrO₂. The obtained sol had a pH value of3.3, a B type viscosity of 193 mPa·s, a content of NO₃ of 3.7% by mass,a particle diameter of 3 to 300 nm as measured by a transmissionelectron microscope, a particle diameter of 96 nm as measured by adynamic light scattering method, a content of zirconia particles havinga particle diameter range of less than 20 nm in all zirconia particlesof 50%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was96.9%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

The sol was preserved at room temperature for 3 months and at this time,the sol had a B type viscosity of 7500 mPa·s (measured with No. 4 rotorat after 60 sec).

Example 5

Into a 3 L glass-made vessel, 342.9 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1976.8 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 80.3 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of10:4, and a pH value of 0.9 (first process). The mixture was transferredinto a glass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 8 hours(second process). The substance obtained after the reaction had no geland was completely converted into a sol. The substance had a content of5% by mass as ZrO₂ and a pH value of 0.7. Next, the sol was washed usingan ultrafiltration apparatus while adding pure water gradually to thesol and was concentrated to thereby obtain an acidic zirconia sol havinga content of 20.5% by mass as ZrO₂. The obtained sol had a pH value of3.4, a B type viscosity of 146 mPa·s (measured with No. 2 rotor at after60 sec), a content of NO₃ of 3.3% by mass, a particle diameter of 3 to300 nm as measured by a transmission electron microscope, a particlediameter of 104 nm as measured by a dynamic light scattering method, acontent of zirconia particles having a particle diameter range of lessthan 20 nm in all zirconia particles of 47%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was97.3%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

The sol was preserved at room temperature for 3 months and at this time,the sol had a B type viscosity of 586 mPa·s (measured with No. 3 rotorat after 60 sec).

Example 6

Into a 3 L glass-made vessel, 96.0 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 2079.2 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 224.8 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of1:4, and a pH value of 2.0 (first process). The mixture was transferredinto a glass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours(second process). The substance obtained after the reaction had no geland was completely converted into a sol. The substance had a content of5% by mass as ZrO₂ and a pH value of 1.6. Next, the sol was washed usingan ultrafiltration apparatus while adding pure water gradually to thesol and was concentrated to thereby obtain an acidic zirconia sol havinga content of 30.4% by mass as ZrO₂. The obtained sol had a pH value of3.5, a B type viscosity of 7.8 mPa·s (measured with No. 2 rotor at after60 sec), a content of NO₃ of 2.0% by mass, a particle diameter of 3 to300 nm as measured by a transmission electron microscope, a particlediameter of 76 nm as measured by a dynamic light scattering method, acontent of zirconia particles having a particle diameter range of lessthan 20 nm in all zirconia particles of 20%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was98.7%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

Example 7

Into a 3 L glass-made vessel, 392.4 g of a zirconium ammonium carbonatesolution (manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) havinga content of 13.1% by mass as ZrO₂ and 1000.9 g of pure water werecharged. While mixing and stirring the resultant mixture solution,thereinto 48.2 g of an alkaline zirconia sol (having a particle diameterof 20 to 300 nm as measured by a transmission electron microscope, aparticle diameter of 82 nm as measured by a dynamic light scatteringmethod, pH of 9.5 and a content of tetramethylammonium hydroxide (TMAH)of 1.0% by mass) having a content of 42.7% by mass as ZrO₂ was chargedand the resultant mixture was stirred for 30 minutes. Into the mixture,while stirring the mixture, a nitric acid aqueous solution of 10% bymass was added intermittently. Nitric acid was gradually added and atthe time when the pH value of the mixture became around 6, the viscositythereof was rapidly elevated, so that a large amount of a gel wasformed. Thereafter, further nitric acid was added and the viscosity wasgradually lowered, so that the formation of the gel became suppressed.Totally 950.4 g of a nitric acid solution of 10% by mass were added tothe mixture and the resultant mixture was stirred for 1 hour, to therebyprepare the raw material mixture. The mixture had a content of 3% bymass as ZrO₂, a mixing ratio (solid content ratio) of a solid content ofzirconium ammonium carbonate converted into ZrO₂ and a solid content ofalkaline zirconia sol converted into ZrO₂ of 10:4 and a pH value of 1.7,and the gel formed in the raw material mixing step has almostdisappeared (first process). The mixture was transferred into aglass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours(second process). The substance obtained after the reaction had no geland was completely converted into a sol. The substance had a content of3% by mass as ZrO₂ and a pH value of 1.1. Next, the sol was washed usingan ultrafiltration apparatus while adding pure water gradually to thesol and was concentrated to thereby obtain an acidic zirconia sol havinga content of 20.2% by mass as ZrO₂. The obtained sol had a pH value of3.2, a B type viscosity of 4.8 mPa·s (measured with No. 2 rotor at after60 sec), a content of NO₃ of 1.9% by mass, a particle diameter of 3 to300 nm as measured by a transmission electron microscope, a particlediameter of 110 nm as measured by a dynamic light scattering method, acontent of zirconia particles having a particle diameter range of lessthan 20 nm in all zirconia particles of 17%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was98.7%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

Example 8

Into a 3 L glass-made vessel, 481.4 g of a zirconium oxychloridesolution (manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) havinga content of 17.7% by mass as ZrO₂ and 1838.3 g of pure water werecharged. While mixing and stirring the resultant mixture solution,thereinto 80.3 g of an alkaline zirconia sol (having a particle diameterof 20 to 300 nm as measured by a transmission electron microscope, aparticle diameter of 82 nm as measured by a dynamic light scatteringmethod, pH of 9.5 and a content of tetramethylammonium hydroxide (TMAH)of 1.0% by mass) having a content of 42.7% by mass as ZrO₂ was chargedand the resultant mixture was stirred for 30 minutes, to thereby preparethe raw material mixture. The mixture had a content of 5% by mass asZrO₂, a mixing ratio (solid content ratio) of a solid content ofzirconium oxychloride converted into ZrO₂ and a solid content ofalkaline zirconia sol converted into ZrO₂ of 10:4, and a pH value of 0.6(first process). The mixture was transferred into a glass-lining coatedautoclave and was subjected to a hydrothermal synthesis reaction whilestirring the mixture at 140° C. for 3 hours (second process). Thesubstance obtained after the reaction had no gel and was completelyconverted into a sol. The substance had a content of 5% by mass as ZrO₂and a pH value of 0.4. Next, the sol was washed using an ultrafiltrationapparatus while adding pure water gradually to the sol and wasconcentrated to thereby obtain an acidic zirconia sol having a contentof 27.5% by mass as ZrO₂. The obtained sol had a pH value of 2.9, a Btype viscosity of 6.0 mPa·s (measured with No. 1 rotor at after 60 sec),a content of Cl of 1.0% by mass, a particle diameter of 3 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of102 nm as measured by a dynamic light scattering method, a content ofzirconia particles having a particle diameter range of less than 20 nmin all zirconia particles of 11%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was95.4%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

Example 9

Into a 3 L glass-made vessel, 244.8 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1414.1 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 55.1 g (intotal) of zirconium oxycarbonate powder (manufactured by Daiichi KigensoKagaku Kogyo Co., Ltd) having a content of 44.5% by mass as ZrO₂ wasgradually charged. After the completion of the charging, while stirring,the resultant mixture was heated to 100° C. and was aged at 100° C. for3 hours. After the completion of the aging, while stirring, the mixturewas cooled. Thereafter, further while mixing and stirring the mixture,thereinto 80.3 g of an alkaline zirconia sol (having a particle diameterof 20 to 300 nm as measured by a transmission electron microscope, aparticle diameter of 82 nm as measured by a dynamic light scatteringmethod, pH of 9.5 and a content of tetramethylammonium hydroxide (TMAH)of 1.0% by mass) having a content of 42.7% by mass as ZrO₂ and 605.7 gof pure water was charged and the resultant mixture was stirred for 30minutes, to thereby prepare the raw material mixture. The mixture had acontent of 5% by mass as ZrO₂, a mixing ratio (solid content ratio) of asolid content of zirconium oxynitrate and zirconium oxycarbonateconverted into ZrO₂ and a solid content of alkaline zirconia solconverted into ZrO₂ of 10:4, and a pH value of 1.0 (first process). Themixture was transferred into a glass-lining coated autoclave and wassubjected to a hydrothermal synthesis reaction while stirring themixture at 140° C. for 3 hours (second process). The substance obtainedafter the reaction had no gel and was completely converted into a sol.The substance had a content of 5% by mass as ZrO₂ and a pH value of 0.8.Next, the sol was washed using an ultrafiltration apparatus while addingpure water gradually to the sol and was concentrated to thereby obtainan acidic zirconia sol having a content of 19.6% by mass as ZrO₂. Theobtained sol had a pH value of 3.5, a B type viscosity of 356 mPa·s(measured with No. 2 rotor at after 60 sec), a content of NO₃ of 3.5% bymass, a particle diameter of 3 to 300 nm as measured by a transmissionelectron microscope, a particle diameter of 87 nm as measured by adynamic light scattering method, a content of zirconia particles havinga particle diameter range of less than 20 nm in all zirconia particlesof 49%.

Further, the yield of a ZrO₂ solid content of the zirconia sol was97.4%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

Comparative Example 1

Into a 3 L glass-made vessel, 342.9 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1942.8 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 114.3 g ofan acidic zirconia sol (manufactured by Nissan Chemical Industries,Ltd.; having a particle diameter of 20 to 300 nm as measured by atransmission electron microscope, a particle diameter of 95 nm asmeasured by a dynamic light scattering method, pH of 4.2) having acontent of 30.0% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of acidic zirconia sol converted into ZrO₂ of10:4, and a pH value of 1.0. The mixture was transferred into aglass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours.The substance obtained after the reaction had no gel and was completelyconverted into a sol. The substance had a content of 5% by mass as ZrO₂and a pH value of 0.7. Next, the sol was washed using an ultrafiltrationapparatus while adding pure water gradually to the sol and wasconcentrated to thereby obtain an acidic zirconia sol having a contentof 21.2% by mass as ZrO₂. The obtained sol had a pH value of 3.2, a Btype viscosity of 32.5 mPa·s (measured with No. 2 rotor at after 60sec), a content of NO₃ of 3.7% by mass, a particle diameter of 3 to 300nm as measured by a transmission electron microscope, a particlediameter of 110 nm as measured by a dynamic light scattering method.Further, the yield of a ZrO₂ solid content of the zirconia sol was98.7%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

However, a content of zirconia particles having a particle diameterrange of less than 20 nm in all zirconia particles was 52%.

Further, when the particles were observed by a transition electronmicroscope, many aggregated particles formed by zirconia particleshaving a particle diameter of less than 20 nm gathering together wereobserved. It is considered that this is because the surface of thezirconia sol particles was charged positively and the oxyzirconium ionZrO²⁺ derived from the zirconium salt (B) was hardly adsorbed to thesurface of the zirconia particles and floated freely in the liquid, sothat the oxyzirconium ion ZrO²⁺ was hydrolyzed during the hydrothermalreaction and fine zirconia particles and extremely fine colloids werereacted with each other to grow as particles.

The acidic zirconia sol was preserved at normal temperature for 40 daysand at this time, the sol had a B type viscosity of 149 mPa·s (measuredwith No. 2 rotor at after 60 sec).

Comparative Example 2

Into a 3 L glass-made vessel, 342.9 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1976.8 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 80.3 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of10:4, and a pH value of 0.9. Next, without subjecting the mixture to aheating treatment, the mixture was washed using an ultrafiltrationapparatus while adding pure water gradually to the mixture and wasconcentrated to thereby obtain an acidic zirconia sol having a contentof 13.8% by mass as ZrO₂. The obtained sol had a pH value of 2.7, a Btype viscosity of 59.5 mPa·s (measured with No. 1 rotor at after 60sec), a content of NO₃ of 2.9% by mass, a particle diameter of 3 to 300nm as measured by a transmission electron microscope, a particlediameter of 129 nm as measured by a dynamic light scattering method.

Further, the yield of a ZrO₂ solid content of the zirconia sol was82.8%, relative to 100% of a ZrO₂ solid content of the raw materialmixture.

However, a content of zirconia particles having a particle diameterrange of less than 20 nm in all zirconia particles was 62%.

Further, the sol maintained a sol state thereof so long as theconcentration of ZrO₂ was low, however, when ZrO₂ was concentrated to15% by mass or more, the sol was rapidly thickened and converted into agel. It is considered that this is because, since the heating treatmentwas not performed, the zirconia particles having a particle diameterrange of less than 20 nm (b) were not crystallized to a certain extentand the surface state thereof was chemically active, so that theinteraction between small particles and extremely fine colloids was highand the sol tended easily to be thickened.

Comparative Example 3

Into a 3 L glass-made vessel, 480.0 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1920.0 g of pure water were charged, tothereby prepare the raw material mixture. The mixture contained 5% bymass of ZrO₂ and had a pH value of 0.6. The mixture was transferred intoa glass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours.The obtained reaction product was in a gel state and could not beconverted into a sol.

Comparative Example 4

Into a 3 L glass-made vessel, 43.6 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 2100.9 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 255.5 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of1:10, and a pH value of 2.5 (first process). The mixture was transferredinto a glass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours(second process). The substance obtained after the reaction had no geland was completely converted into a sol. The substance had a content of5% by mass as ZrO₂ and a pH value of 2.2. Next, the sol was washed usingan ultrafiltration apparatus while adding pure water gradually to thesol and was concentrated to thereby obtain an acidic zirconia sol havinga content of 26.6% by mass as ZrO₂. The obtained sol had a pH value of3.3, a B type viscosity of 18.0 mPa·s (measured with No. 1 rotor atafter 60 sec), a content of NO₃ of 1.2% by mass, a particle diameter of3 to 300 nm as measured by a transmission electron microscope, aparticle diameter of 86 nm as measured by a dynamic light scatteringmethod.

Further, the yield of a ZrO₂ solid content of the zirconia sol was98.5%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

However, a content of zirconia particles having a particle diameterrange of less than 20 nm in all zirconia particles was 9%.

Since the obtained acidic zirconia sol had a low content of zirconiaparticles having a particle diameter of less than 20 nm, it was near toa conventional acidic zirconia sol and could not exhibit binderproperties.

Comparative Example 5

Into a 3 L glass-made vessel, 436.4 g of a zirconium oxynitrate solution(manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd) having a contentof 25.0% by mass as ZrO₂ and 1938.1 g of pure water were charged. Whilemixing and stirring the resultant mixture solution, thereinto 25.5 g ofan alkaline zirconia sol (having a particle diameter of 20 to 300 nm asmeasured by a transmission electron microscope, a particle diameter of82 nm as measured by a dynamic light scattering method, pH of 9.5 and acontent of tetramethylammonium hydroxide (TMAH) of 1.0% by mass) havinga content of 42.7% by mass as ZrO₂ was charged and the resultant mixturewas stirred for 30 minutes, to thereby prepare the raw material mixture.The mixture had a content of 5% by mass as ZrO₂, a mixing ratio (solidcontent ratio) of a solid content of zirconium oxynitrate converted intoZrO₂ and a solid content of alkaline zirconia sol converted into ZrO₂ of10:1, and a pH value of 0.8 (first process). The mixture was transferredinto a glass-lining coated autoclave and was subjected to a hydrothermalsynthesis reaction while stirring the mixture at 140° C. for 3 hours(second process). The substance obtained after the reaction had no geland was completely converted into a sol. The substance had a content of5% by mass as ZrO₂ and a pH value of 0.6. Next, the sol was washed usingan ultrafiltration apparatus while adding pure water gradually to thesol and was concentrated to thereby obtain an acidic zirconia sol havinga content of 9.1% by mass as ZrO₂. The obtained sol had a pH value of3.2, a B type viscosity of 74.0 mPa·s (measured with No. 1 rotor atafter 60 sec), a content of NO₃ of 1.9% by mass, a particle diameter of3 to 300 nm as measured by a transmission electron microscope, aparticle diameter of 96 nm as measured by a dynamic light scatteringmethod.

Further, the yield of a ZrO₂ solid content of the zirconia sol was96.4%, relative to 100% of a ZrO₂ solid content of the mixture in thefirst process.

However, a content of zirconia particles having a particle diameterrange of less than 20 nm in all zirconia particles was 53%. The amountof small particles was larger than that of large particles, so that whenthe acidic zirconia sol has a high concentration, a stable sol cannot beobtained.

As described in Comparative Example 1, when an acidic zirconia solinstead of the alkaline zirconia sol (A) and zirconium oxynitratecorresponding to the zirconium salt (B) were used, the obtained zirconiasol had a content of zirconia particles having a particle diameter rangeof less than 20 nm of more than 50% and in the obtained zirconia sol, alarge amount of an aggregated structure of small particles having aparticle diameter of less than 20 nm was observed, so that the acidiczirconia sol according to the present invention could not be obtained.

As described in Comparative Example 2, even when the alkaline zirconiasol (A) and zirconium oxynitrate corresponding to the zirconium salt (B)were used, when in the following process, the hydrothermal reaction at80 to 250° C. was not performed, the obtained zirconia sol had a contentof zirconia particles having a particle diameter range of less than 20nm of more than 50% and the surface of the formed small particles havinga particle diameter of less than 20 nm had activity, so that by thesesmall particles, a gelation was induced.

As described in Comparative Example 3, when the alkaline zirconia sol(A) was not used and only zirconium oxynitrate corresponding to thezirconium salt (B) was used, as described in “Background Art”, the saltshould be hydrolyzed in an acidic region and heated to produce fineparticles, however, the reaction system became unstable and a gelationwas caused.

In Examples 1 to 9 of the present invention, in the presence of thealkaline zirconia sol (A), by hydrolyzing a zirconium salt, largeparticles derived from the alkaline zirconia sol (A) and small particlesderived from the hydrolysis of the zirconium salt (B) were present inthe ratio B/A of 0.2 to 5.0, so that a stable acidic zirconia sol havinga wide range of particle diameter could be obtained.

However, as described in Comparative Example 4, when the ratio B/A isless than 0.2, the content of zirconia particles having a particlediameter range of less than 20 nm becomes less than 10% and a desiredacidic zirconia sol cannot be obtained. On the other hand, as describedin Comparative Example 5, when the ratio B/A is more than 5.0, thecontent of zirconia particles having a particle diameter range of lessthan 20 nm becomes more than 50% and a desired acidic zirconia solcannot also be obtained. When the obtained acidic zirconia sol has ahigh concentration, it cannot be a stable sol.

INDUSTRIAL APPLICABILITY

The acidic zirconia sol according to the present invention has a wideparticle diameter distribution and is stable, so that it can be appliedin many applications, such as a binder for molding processing of variousrefractories, a binder for various catalysts, an impregnation treatment,a paint for coating, as well as molding processing of an inorganic fibersuch as a ceramic fiber, shaping of a mold for a precision casting, asurface treatment of a fiber, and a fuel cell.

1. An acidic zirconia sol having a particle diameter of from 76 nm to108 nm as measured by a dynamic light scattering method comprising:zirconia particles (a) having a particle diameter ranging from 20 to 300nm in a content of 90 to 50% by mass, based on the mass of all zirconiaparticles; and zirconia particles (b) having a particle diameter of lessthan 20 nm in a content of 10 to 50% by mass, based on the mass of allzirconia particles.